Method to produce a veneered element

ABSTRACT

A method to produce a veneered element, the method including applying a first layer on a substrate, applying a second layer on a veneer layer, applying the veneer layer with the second layer applied thereto on the first layer, such that the second layer is facing the first layer, pressing the first layer, the second layer and the veneer layer together to form a veneered element, thereby material originating from the second layer permeates into the veneer layer, and wherein, after pressing, the first layer is visible through a crack, cavity, hole and/or knot of the veneer layer. Also, a veneered element.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of Swedish Application No. 1850031-4, filed on Jan. 11, 2018. The entire contents of Swedish Application No. 1850031-4 are hereby incorporated herein by reference in their entirety.

TECHNICAL FIELD

The present application relates to a method to produce a veneered element, and such a veneered element.

TECHNICAL BACKGROUND

Floor coverings having a wooden surface may be of several different types. Solid wood floorings are formed of a solid piece of wood in form of a plank. Engineered wood floorings are formed of a surface layer of wood glued to a core. The core may be a lamella core or a wood-based panel, such as plywood, MDF or HDF. The wooden surface layer may, as an example, have a thickness of 2-10 mm.

A wooden floor covering may also be formed by gluing a wood veneer to a core, for example, a wood-based panel, such as particleboard, MDF or HDF. Wood veneer is a thin wood layer, for example having a thickness of 0.2-1 mm. A flooring with a separate surface layer glued to a core of, for example, HDF or plywood is more moisture stable than solid wood floorings.

Compared to solid wood and engineered wood floorings, wood veneer floorings can be produced to a lower cost since only a thin wood layer is used. However, a wood veneer layer cannot be sanded as a solid wood or engineered wood flooring can be.

As an alternative to wood floorings, laminate floorings are also available. Direct pressed laminated flooring usually comprises a core of a 6-12 mm fibre board, a 0.2 mm thick upper decorative surface layer of laminate and a 0.1-0.2 mm thick lower balancing layer of laminate, plastic, paper or like material.

A laminate surface conventionally comprises two paper sheets; a 0.1 mm thick printed decorative paper and a 0.05-0.1 mm thick transparent overlay intended to protect the decorative paper from abrasion. The transparent overlay, which is made of α-cellulose fibres, comprises small hard and transparent aluminium oxide particles, which gives the surface layer a high wear resistance.

The printed decorative paper and the overlay are impregnated with melamine resin and laminated to a wood fibre based core under heat and pressure. The two papers have prior to pressing a total thickness of about 0.3 mm and they are after pressing compressed to about 0.2 mm.

A wood veneer flooring may have a lower impact resistance than laminate floorings and the production cost is high, compared to laminate floorings, when high quality veneers are to be used.

Recently new “paper free” floor types have been developed with a solid surface comprising a substantially homogenous powder mix of fibres, binders and wear resistant particles. The mix is applied on a wood-based panel, such as MDF or HDF, and subsequently heat and pressure are applied to the mix to form a surface layer on the panel, as disclosed in WO 2009/065769. Such a surface layer is marketed under the trademark NADURA®.

WO 2009/065769 also discloses a thin surface layer, such as wood veneer layer, which is applied on a sub-layer comprising, for example, cork or wood fibres mixed with a binder. The sub-layer is applied on wood fibre based core.

U.S. Pat. No. 2,831,794 discloses a process for manufacturing veneer panels. A green veneer is applied on a mat of resin coated core particles of ligno-cellulose fibrous particles. Adhesive is applied on the veneer to bond the veneer to the fibrous core, and to form a dense surface zone in the fibrous core. The material of the core serves to fill knot holes or open flaws in the veneer. When heat and pressure are applied, the result is the formation of a panel, wherein the resin coated core particles fill whatever flaws or holes that would otherwise be present in the veneer.

U.S. Pat. No. 2,419,614 discloses a coated wood product wherein a plywood is coated by a covering or overlay material consisting of mixtures of sawdust and synthetic resin. The veneer layer is coated by the covering or overlay material such that the veneer is no longer visible. The covering forms the uppermost layer of the product.

WO 2015/105455 discloses that holes and cracks of a wood veneer can be filled with material from a sub-layer comprising wood fibres and a binder during pressing. Thereby, a wood veneer of lower quality can be used.

WO 2015/105456 discloses a method of controlling permeation of a sub-layer through a wood veneer during pressing. Thereby, the design of the wood veneer after pressing can be controlled, by controlling the degree of permeation of materials from the sub-layer through the wood veneer.

In the above description, the different types of products have been described with reference to floorings. However, the same material and problems apply for other types of building panels, such as wall panels, ceiling panels, and for furniture components.

SUMMARY

It is an object of at least embodiments of the present invention to provide an improvement over the above described techniques and known art.

A further object of at least embodiments of the present invention is to provide improved designs of veneer layers.

A further object of at least embodiments of the present invention is to further control the design of a veneer layer after pressing.

A further object of at least embodiments of the present invention is to provide a veneer layer with defects, such as holes, cracks and knots, filled with material from a layer arranged below the veneer layer without affecting other portions of the veneer layer.

At least some of these and other objects and advantages that will be apparent from the description have been achieved by a method to produce a veneered element according to a first aspect of the invention. The method comprises applying a first layer on a substrate, applying a second layer on a veneer layer, applying the veneer layer with the second layer applied thereto on the first layer such that the second layer is facing the first layer, pressing the first layer, the second layer and the veneer layer together to form a veneered element, thereby material originating from the second layer permeates into the veneer layer, and wherein, after pressing, the first layer is visible through a defect, such as a crack, cavity, hole and/or knot, of the veneer layer.

Defect includes any crack, cavity, hole and/knot in the veneer layer. A defect may include any portion of the veneer layer not being solid and/or dense. Dense portions of the wood veneer are the portions of the veneer layer, where there are no visible by eye defects, i.e. macroscopic defects, such as cracks, cavities, holes and/or knots.

Cracks, cavities, holes and/knots may also be desired and formed during the production process, and thus forming desired defects of the veneer layer.

An advantage of at least embodiments of the first aspect is that the design of the veneer layer element can be further controlled by applying the veneer layer on two layers having different properties. The formulation of the first layer may be different from the formulation of the second layer. For example, the first layer may be pigmented or dyed, and the second layer may be free from pigments and/or dyes. As another alternative, the first layer may have a colour being different from the colour of the second layer. Thereby, the design of the veneer after pressing can be controlled.

During pressing, material from the second layer permeates at least partly into the veneer layer and/or through the veneer layer. The second layer, at least partly permeating into the veneer layer, at least partly or completely prevents the first layer from permeating into or through the veneer layer, as compared to an embodiment wherein only a single layer is provided. However, in any defect of the veneer layer, such as cracks, cavities, holes and/or knots, the first layer is visible through any crack, cavity, hole and/or knot.

Permeating means that the second layer is diffuses or penetrates into the microscopic structure of the veneer layer, the structure not visible by the eye, such as wood pores.

Thereby, defects, such as cracks, cavities, holes and knots, are visible and filled with material from the first layer. For example, the first layer may be coloured in a darker colour than the colour of the veneer layer. Thereby, defects, such as cracks, cavities, holes and knots, are visible and coloured with a dark colour.

Thereby, when the first layer is seen through the defects such as cracks, cavities holes and/or knots, the defects are seen as having a colour of the first layer.

At the same time, dark colored particles from the first layer at least partially prevented from permeating into the dense part of the veneer layer by the second layer. Thereby, the undesired coloring of the dense parts of the veneer layer is at least partially prevented while the defects are perceived as dark colored. Thereby the veneer layer has more aesthetica) appearance, which is more appealing to a consumer.

However, for some designs, it may be undesired to change the design of the veneer layer itself by permeating coloured material through portions of the veneer layer other than defects, such as through solid parts of the veneer layer, i.e., dense parts of the veneer. By arranging the second layer on the first layer, the veneer layer is permeated by the second layer instead, and the second layer may at least partly prevent the first layer from permeating into the veneer layer. Thereby, the veneer layer may be substantially unaffected by the first layer after pressing. For example, by using a second layer being substantially free from pigments of dyes, permeation of the second layer through the veneer layer results in substantially no change of the design of the veneer layer, or at least a less visible change of the design of the veneer layer. Thereby, defects, such as knots, holes and cracks, are visible and filled with material having one colour, and the rest of the veneer layer remains substantially unaffected.

As another example, the second layer may have different colour than the first layer, such that any defect, such as a knot, hole and crack, have one colour (primarily from the first layer) and material permeating into the veneer layer has another colour (primarily from the second layer). Thereby, the veneer layer may be stained in one colour (primarily from the second layer), for example with a light colour or a colour corresponding to a natural colour of the veneer layer, and defects, such as knots, holes and cracks, may have a different colour after pressing, for example a dark colour (primarily from the first layer).

The veneer layer may be or comprise a wood veneer or a cork veneer.

During pressing, a crack, cavity, hole and/or knot of the veneer layer may be at least partially filled with material originating from the first layer. Preferably, the material filling defect, such as a crack, cavity, hole and/or knot, is flush with an upper surface of the veneer layer after pressing.

During pressing, material originating from the second layer may permeate into the veneer layer. That is, permeating into the material of the veneer, as opposed to filling in a defect. The material originating from the second layer may permeate into the veneer layer and/or through the veneer layer. During pressing, the second layer may prevent material originating from the first layer from permeating into and/or through the veneer layer. Thereby, the veneer layer, except any defects, may remain substantially unaffected by material originating from the first layer after pressing.

Applying the second layer on the veneer layer may comprise applying a liquid on the veneer layer, and subsequently applying a dry powder on the veneer layer for forming the second layer.

The second layer may be applied as a slurry.

No or substantially no second layer may be attached to at a crack, cavity, hole and/knot of the veneer layer.

The first layer may comprise pigments and/or dyes.

The first layer may have a substantially uniform colour. The first layer may be substantially uniformly coloured over its horizontal extension. The first layer may be substantially uniformly coloured in its vertical extension.

The second layer may have a substantially uniform colour. The second layer may be substantially uniformly coloured over its horizontal extension. The second layer may be substantially uniformly coloured in its vertical extension.

The second layer may be free from pigments and dyes.

After pressing, the second layer may be transparent, or at least translucent.

The second layer may have a different colour than the first layer after pressing. The second layer may stain the veneer layer after pressing.

The second layer may comprise pigments and/or dyes.

The first layer may comprise a thermosetting binder. The thermosetting binder may be an amino resin, for example, melamine formaldehyde, urea formaldehyde, or a combination or co-polymer thereof.

The second layer may comprise a thermosetting binder. The thermosetting binder may be an amino resin, for example, melamine formaldehyde, urea formaldehyde, or a combination or co-polymer thereof.

In one embodiment, the first layer and/or the second layer may comprise thermoplastic binder.

The first layer may be applied as a dry powder. For example, the binder of the first layer may be applied as a dry powder. Alternatively, the first layer may be applied in liquid form, for example by applying the binder in liquid form.

The second layer may be applied as a dry powder. For example, the binder of the second layer may be applied as a dry powder. Alternatively, the second layer may be applied in liquid form, for example by applying the binder in liquid form.

The second layer may be applied in an amount of 5-200 g/m2. By applying at least 5-200 g/m2, the second layer may prevent the first layer from permeating into the veneer layer during pressing. If the second layer is applied in powder form, the second layer may be applied in an amount of at least 50 g/m2, preferably at least 100 g/m2. If the second layer is applied in liquid form, the second layer may be applied in an amount of 10-100 g/m2, preferably 20-50 g/m2.

The first and/or the second layer may further comprise fillers. The fillers may be particles or fibres, for example wood fibres or particles, or mineral particles or fibres. The wood particles may be lignocellulosic particles and/or cellulosic particles. The wood particles may be at least partially bleached.

The first and/or the second layer may comprise wear resistant particles and/or scratch resistant particles. Preferably, at least the second layer comprises wear resistant particles and/or scratch resistant particles.

The first layer may comprise a paper sheet, preferably a resin impregnated paper sheet. In an embodiment wherein the first layer comprises a paper sheet, the paper sheet may be coloured. In an embodiment wherein the second layer comprises a paper sheet, the paper sheet may be an overlay sheet, for example of the type used for laminate flooring. After pressing, such an overlay sheet is transparent. The first layer may comprise a thermoplastic sheet.

The substrate may comprise a wood-based board such MDF, HDF, particleboard, a thermoplastic board, a plywood, a lamella core, a veneer layer, such as a wood veneer or cork veneer, a sheet, such as paper sheet, a non-woven, or a conveyor. In one embodiment, the substrate may be included in the veneered element after pressing, by pressing, the substrate, the first layer, the second layer and the veneer layer together. In one embodiment, the veneered element may be removed from the substrate after pressing.

According to a second aspect of the present invention, a veneered element is provided. The veneered element comprises a substrate, a first layer arranged on the substrate, a second layer arranged on the first layer, and a veneer layer arranged on the second layer, wherein the first layer is visible through a hole, crack and/or knot of the veneer layer, and wherein material originating from the second layer is present in the veneer layer.

Embodiments of the second aspect of the present invention incorporates all the advantages of the first aspect of the invention, which previously has been discussed, whereby the previous discussion is applicable also for the veneered element.

The veneer layer may be or comprise a wood veneer or a cork veneer.

No material originating from the second layer may be present at a hole, crack or knot of the veneer layer.

The crack, cavity, hole and/or knot of the veneer layer may be at least partially filled with material originating from at least the first layer. Preferably, the material filling defects as a crack, cavity, hole and/or knot is flush with an upper surface of the veneer layer.

The second layer may be adapted to prevent material originating from the first layer from may permeate into and/or through the veneer layer. Thereby, the veneer layer, except any defects, may remain substantially unaffected by material from the first layer after pressing.

The second layer may be transparent or translucent. In the context of the present invention translucent means that the second layer allowing light, but not detailed shapes, to pass through; semi-transparent.

The first layer may comprise pigments and/or dyes.

The first layer may have a substantially uniform colour. The first layer may be substantially uniformly coloured over its horizontal extension. The first layer may be substantially uniformly coloured in its vertical extension.

The second layer may have a substantially uniform colour. The second layer may be substantially uniformly coloured over its horizontal extension. The second layer may be substantially uniformly coloured in its vertical extension.

The second layer may be free from pigments and dyes.

The second layer may have a different colour than the first layer after pressing. The second layer may stain the veneer layer after pressing.

The first layer may comprise a thermosetting binder. The thermosetting binder may be an amino resin, for example, melamine formaldehyde, urea formaldehyde, or a combination or co-polymer thereof.

The second layer may comprise a thermosetting binder. The thermosetting binder may be an amino resin, for example, melamine formaldehyde, urea formaldehyde, or a combination or co-polymer thereof.

In one embodiment, the first layer and/or the second layer may comprise a thermoplastic binder. The first layer may comprise thermoplastic foil.

The first and/or the second layer may further comprise fillers. The fillers may be particles or fibres, for example wood fibres or particles, or mineral particles or fibres. The wood particles may be lignocellulosic particles and/or cellulosic particles. The wood particles may be at least partially bleached.

The first and/or the second layer may comprise wear resistant particles and/or scratch resistant particles. Preferably, at least the second layer comprises wear resistant particles and/or scratch resistant particles.

The first layer may comprise a paper sheet, preferably a resin impregnated paper sheet. In an embodiment wherein the first layer comprises a paper sheet, the paper sheet may be coloured. In an embodiment wherein the second layer comprises a paper sheet, the paper sheet may be an overlay sheet, for example of the type used for laminate flooring. After pressing, such an overlay sheet is transparent.

The substrate may comprise a wood-based board, such as MDF, HDF, particleboard, a thermoplastic board, a plywood, a lamella core, a veneer layer, such as a wood veneer or cork veneer, a sheet, such as paper sheet, a non-woven, or a conveyor. In one embodiment, the substrate may be included in the veneered element after pressing, by pressing, the substrate, the first layer, the second layer and the veneer layer together. In one embodiment, the veneered element may be removed from the substrate after pressing.

According to a third aspect of the invention, a method to produce a veneered is provided. The method may comprise applying a first layer on a substrate, applying a liquid on a veneer layer including cracks, cavities, holes and/or knots, subsequently applying a dry powder on the veneer layer, pressing the substrate, the first layer and the veneer layer with the dry powder together for forming a veneered element.

Embodiments of the third aspect of the present invention may incorporate all the advantages of the first aspect of the invention, which previously has been discussed, whereby the previous discussion is applicable also for the veneered element.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will by way of example be described in more detail with reference to the appended schematic drawings, which show embodiments of the present invention.

FIGS. 1A-1C illustrates a method of a producing a veneered element according to an embodiment.

FIG. 2 illustrates a cross-section of an embodiment of a veneered element.

FIG. 3 illustrates an embodiment of a veneered element.

DETAILED DESCRIPTION

FIGS. 1A-1C show a method of producing a veneered element 10. The veneered element 10 may be a furniture component, a building panel, such as a floor panel, a ceiling panel, a wall panel, a door panel, a worktop, skirting boards, mouldings, edging profiles, etc. The method comprises providing a substrate 1. The substrate 1 is preferably a pre-fabricated substrate, manufactured prior to the method of producing the veneered element 10. The substrate 1 may be a board, for example, a wood-based board as shown in the embodiment shown in FIGS. 1-3. The wood-based board may be a wood fibre based board, such as MDF, HDF, particleboard, etc., or a plywood board. In other embodiments, the substrate 1 may be a Wood Plastic Composite (WPC). The substrate 1 may be a mineral composite board. The substrate 1 may be a fibre cement board. The substrate 1 may be magnesium oxide cement board. The substrate 1 may be a ceramic board. The substrate 1 may be a plastic board, such as a thermoplastic board. In another embodiment, the substrate 1 may be a carrier, such as sheet of paper, a veneer layer, or non-woven, or a conveyor. The carrier may be a resin impregnated sheet, such as a resin impregnated paper.

In FIG. 1A, a first layer 2 a is applied on a first surface of the substrate 1. In the embodiment shown in FIG. 1A, the first layer 2 a is applied in powder form 21. The powder 21 adapted to form the first layer 2 a is applied by scattering, as shown in FIG. 1A, for example by a scattering device 20. The first layer 2 a may also be applied as granules. In other embodiments, the first layer 2 a may be applied as a liquid, as a paste, a sheet, etc. The first layer 2 a may be applied by roller coating, spraying, etc.

In the context of the present invention powders are finally divided chemicals in a dry form, more precisely subdivided solids containing constituent individual particles.

In the context of the present invention granules are typically understood as aggregation of fine particles to form larger particles.

In one embodiment (not shown), the first layer 2 a comprises a sheet impregnated with a thermosetting binder. The sheet may be paper sheet. The sheet may be coloured, and/or the binder solution used to impregnate the sheet may be coloured, such that sheet becomes coloured during impregnation.

The first layer 2 a comprises pigments and/or dyes. Preferably, pigments and/or dyes may be darker than the natural colour of the veneer layer which is to be applied later in the process. The first layer 2 a preferably has a uniform colour. The first layer 2 a is preferably uniformly coloured in the horizontal direction. The first layer 2 a is preferably uniformly coloured in the vertical direction.

Moisture may be applied to the first layer 2 a. The first layer 2 a may be dried, for example, by applying IR or NIR.

In FIG. 1B, a liquid or moisture is applied on a veneer layer 3. The veneer layer 3 may be a wood veneer or a cork veneer. The veneer has a porous structure, thus being permeable. The veneer layer 3 may have a thickness of about 0.2 to 1 mm. The veneer layer 3 may be continuous or non-continuous. The veneer layer 3 may be formed of several veneer pieces. The veneer pieces may be over-lapping or non-overlapping. A gap may be formed between the veneer pieces.

The veneer layer 3 may comprise defects 6, such as holes, knots and/or cracks. By defects are meant both naturally occurring defects in the veneer, such as holes, cavities, knots and/or cracks, and defects, such as holes, cavities, knots and/or cracks, formed by, for example, abrasive machining, punching, tearing, brushing, stretching, etc., prior to pressing.

The liquid may be water, a solvent, a binder, etc. The liquid may be applied by a spraying device 24.

In a subsequent step, a second layer 2 b is applied on the veneer layer 3. In the embodiment shown in FIG. 1B, the second layer 2 b is applied in powder form 23. The powder 23 adapted to form the second layer 2 b is applied by scattering, as shown in FIG. 1A, for example by a scattering device 22. The second layer 2 b may also be applied as granules. In other embodiments, the second layer 2 b may be applied as a liquid, as a paste, a sheet, etc. The second layer 2 b may be applied by roller coating, spraying, etc.

Since a liquid or moisture has been applied to the veneer layer 3, the second layer 2 b applied in powder form will adhere to dense parts of the veneer layer 3. However, no or substantially no powder will adhere to any crack, cavity, hole and/or knot of the veneer layer 3, since there is no material to adhere to. The cracks, cavities, holes and/or knots are cavities in the veneer layer 3, thus lacking the ability to adhere to powder of the second layer 2 b. Thereby, the second layer 2 b is present only at the solid/dense portions of the veneer layer 3. No or substantially no second layer 2 b is present at any crack, cavity, hole and/or cavity of the veneer layer 3.

The second layer 2 b arranged at the veneer layer 3 may be stabilized, for example by applying IR or NIR. Thereafter, the veneer layer 3 with the second layer 2 b adhered thereto may be handled, for example, stacked in sheets or rolled to a continuous roll.

In one embodiment, the second layer 2 b is free from pigments and dyes. The second layer 2 b may be uncoloured.

In one embodiment, the second layer 2 b comprises pigments and/or dyes. The colour of the second layer 2 b may be different from the colour of the first layer 2 a. The colour of the second layer 2 b may be adapted to stain the veneer layer 3.

The first layer 2 a and the second layer 2 b comprises a binder. The binder may be a thermosetting binder, a thermoplastic binder, or a combination thereof. The binder may be wood mastic, wood filler or any other type of putty-like paste. The thermosetting binder may be an amino resin, such as melamine formaldehyde resin, phenol formaldehyde resin, urea formaldehyde resin, or a combination thereof. Urea formaldehyde resin may be used, alone or in combination with melamine formaldehyde resin, to reduce tension formed by the first layer 2 a and/or the second layer 2 b during curing, compared to when melamine formaldehyde resin is used only. The thermoplastic binder may be polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyurethane (PU), polyvinyl alcohol (PVOH), polyvinyl butyral (PVB), polyvinyl acetate (PVAc), and/or thermoplastic elastomer (TPE), or a combination thereof.

The binder described above may be in powder form when applied.

In one embodiment, the first layer 2 a comprises urea formaldehyde resin, and the second layer comprises melamine formaldehyde resin. Melamine formaldehyde resin flows more than urea formaldehyde resin, which may result in permeation, but gives good transparency.

In one embodiment, the second layer 2 b comprises urea formaldehyde resin, and the first layer 2 a comprises melamine formaldehyde resin. Urea formaldehyde resin flows less than melamine formaldehyde resin. In order to improve the transparency of the urea formaldehyde resin, the binder may be applied in liquid form.

In one embodiment, both the first and the second layer comprise urea formaldehyde resin.

The first layer 2 a and/or the second layer 2 b may be formed of a mix comprising a binder of the above described type and fillers. The mix may further comprise pigments as described above. The mix may further comprise additives. The mix may further comprise wear and/or scratch resistant particles. As an alternative to a mix, the binder, fillers, pigments, additives and any other component may be applied separately on the substrate 1.

The fillers may be particles or fibres, for example wood fibres or particles, or mineral particles or fibres. The wood particles may be lignocellulosic particles and/or cellulosic particles. The wood particles may be at least partially bleached. The fillers may be rice, straw, corn, jute, linen, flax, cotton, hemp, bamboo, bagasse or sisal particles or fibres. The first and/or the second layer 2 a, 2 b may comprise starch, such as maize starch, potato starch, etc.

If the second layer 2 b comprise wood fibres or particles, the fibres or particles are preferably at least partially bleached.

The fillers may be fillers having sound-absorbing properties, such as cork particles and/or barium sulphate (BaSO4).

The additives may be wetting agents, anti-static agents, such as carbon black, and heat-conducting additives, such as aluminium. Other possible additives are magnetic substances.

The first layer 2 a and/or the second layer 2 b may also comprise a foil or a sheet.

Additives, such as blowing agents may be included in the first and/or second layers 2 a, 2 b. The blowing agents may be physical foaming agents, such as EXPANCEL®, and/or chemical blowing agents, such as AIBN (azoisobutyronitrile) or ADC (azodicarbonamide).

The first layer 2 a may comprise a blowing agent for improving filling of any cracks, cavities, holes and/or cavities.

The wear and/or scratch resistant particles may be aluminium oxide particles and/or silica particles.

In one embodiment, the first layer 2 a and/or the second layer 2 b consists essentially of the binder and optionally additives, meaning that at least 90 wt % of the first and/or second layer 2 a, 2 b is the binder and optional additive(s). In one embodiment, the first layer 2 a and/or the second layer 2 b is free from any fibres and/or fillers. Additives may be but not limited to wetting agents, anti-static agents, such as carbon black, heat conductive additives such as aluminum; magnetic substances; blowing agents, such as physical foaming agents (for example, EXPANCEL® or chemical blowing agents such as AIBN (azoisobutyronitrile) or ADC (azodicarbonamide); catalysators.

The first layer 2 a may be applied in an amount of 100-300 g/m2, preferably 150-250 g/m2, such as about 200 g/m2. The amount of binder applied for the first layer 2 a may be 50-150 g/m2, preferably 75-125 g/m2, such as about 100 g/m2. The first layer 2 a may comprise the binder in an amount of 30-80 wt %, preferably in an amount of 40-60 wt %, such as about 50 wt %.

The second layer 2 b may be applied in an amount of 100-300 g/m2, preferably 150-250 g/m2, such as about 200 g/m2 if applied in powder form. The amount of binder applied in powder form for the second layer 2 b may be 50-150 g/m2, preferably 75-125 g/m2, such as about 100 g/m2. The second layer 2 b may comprise the binder in an amount of 30-80 wt %, preferably in an amount of 40-60 wt %, such as about 50 wt %.

In liquid form, the second layer may be applied in an amount of 5-100 g/m2.

The first layer 2 a may be pre-pressed prior to applying the wood veneer layer 3 with the second layer 2 b adhered thereto. The veneer layer 3 with the second layer 2 b may be pre-pressed prior to pressing.

In FIG. 1C, the veneer layer 3 with the second layer 2 b adhered to thereto is arranged on the first layer 2 a, arranged on the substrate 1. The first layer 2 a is facing the second layer 2 b.

A balancing layer may also be applied on a lower surface of the substrate 1. The balancing layer may be a powder based balancing layer being applied as a powder. The powder based balancing layer may comprise wood particles, such as lignocellulosic and/or cellulosic particles and a binder, preferably a thermosetting binder, such as an amino resin. The balancing layer may be a resin impregnated paper, preferably impregnated with a thermosetting binder. The balancing layer may comprise a veneer layer, such as a wood veneer or cork veneer. The balancing layer may comprise a veneer layer, such as wood veneer or cork veneer arranged on a sub-layer comprising wood particles, such as lignocellulosic and/or cellulosic particles and a binder, preferably a thermosetting binder, such as an amino resin.

As shown in FIG. 1C, when the veneer layer 3 with the second layer 2 b adhered thereto is arranged on the first layer 2 a, arranged on the substrate 1, pressure is applied to the veneer layer 3 and/or the substrate 1. The pressure may be applied by continuous press 30 or in a discontinuous press (not shown). Preferably, heat is also applied.

After pressing, a veneered element 10 is formed, as shown in FIGS. 2 and 3. In one embodiment, the veneer layer 3, the first and second layers 2 a, 2 b, and the substrate 1 are pressed together such that the veneered element 10 includes the substrate 1. In other embodiments, the veneered element 10 is removed from the substrate 1 after pressing.

After pressing, the second layer 2 b may be transparent or at least translucent. The second layer 2 b may be coloured or stained, but may remain at least translucent. The second layer 2 b may be transparent after pressing by having a high binder content. If the second layer 2 b comprises wood fibres or particles, the wood fibres or particles are preferably cellulosic fibres or particles. The wood fibres or particles are preferably at least partially bleached.

During pressing, material from the second layer 2 b may permeate through the veneer layer 3. Material from the second layer 2 b may permeate partially through the veneer layer 3 or completely through the veneer layer 3.

After pressing, defects 6, such as holes, knots and cracks are filled with material from the first layer 2 a, as shown in FIGS. 2 and 3. Preferably, defects 6, such as holes, knots and cracks, are filled with material from the first layer 2 a. Preferably, material from the first layer 2 a is flush with an upper surface 4 of the veneer layer 3.

During pressing, the second layer 2 b, arranged on the first layer 2 a, prevents the first layer 2 a from at least from completely permeating through solid/dense parts of the veneer layer 3. Thereby, the veneer layer 3 remains substantially unaffected by the first layer 2 a. However, at defects 6 of the veneer layer 3, such as holes, knots and cracks, the first layer 2 a fills defects 6, such as holes, knots and cracks. Thereby, it is possible to obtain a visible design of the veneer layer 3 wherein defects 6, such as holes, knots and cracks, of the veneer layer are coloured with a darker colour than the rest of the veneer layer 3. The rest of the veneer layer remains substantially unaffected by the first layer 2 a, such that the veneer layer 3 is not coloured by the first layer 2 a. By substantially unaffected is meant compared to how an appearance the veneer layer 3 would have after pressing if being arranging on the first layer 2 a only.

In one embodiment, the second layer 2 b is free from any pigments and/or dyes. Thereby, the veneer layer 3 is not coloured by any pigments or dyes from the second layer 2 b after pressing. The veneer layer 3 will only be affected by, for example by the binder of the second layer 2 b. After pressing, the veneer layer 3 has its original appearance, or at least substantially its original appearance, while any defects 6, such as knots, holes and cracks, will be visible and filled with material having the colour of the first layer 2 a.

In one embodiment, the second layer 2 b comprises pigments and/or dyes. Preferably, the colour of the second layer 2 b is different from the colour of the first layer 2 a. Thereby, solid/dense parts of the veneer layer 3 may be coloured by one colour (primarily the color of the second layer) after pressing by the permeation of the second layer 2 b during pressing, while any defects 6, such as knots, holes and cracks, will be visible and coloured in a different colour (primarily the color of the first layer), due to the first layer 2 a filling or at least partially filling the defects 6.

Depending on several parameters, such as binder concentration, in the first and second layers 2 a, 2 b, moisture content in the first and second layers 2 a, 2 b, pressure applied, gas pressure and filler concentration in the first and second layers 2 a, 2 b, and depending on the thickness of the veneer layer, permeation of the first and the second layer 2 a, 2 b can be controlled. By controlling these parameters, the degree of permeation of the first layer 2 a and/or the second layer 2 b through the veneer layer can be controlled.

For example, in one embodiment wherein the first layer 2 a comprises urea formaldehyde as the binder, and the second layer 2 b comprises urea formaldehyde as the binder, the first layer 2 a is prevented from permeating through the veneer layer 3 by the second layer 2 b. Thereby, after pressing, the solid/dense parts of the veneer layer 3 remains unaffected from permeation of material from the first layer 2 a.

In one embodiment wherein the first layer 2 a comprises urea formaldehyde resin as the binder, and the second layer 2 b comprises melamine formaldehyde as the binder, the first layer 2 a is not completely prevented from permeating through the veneer layer 3 by the second layer 2 b. In this embodiment, some material from the first layer 2 a may permeate through the veneer layer 3, due to the melamine formaldehyde resin of the second layer 2 b flowing more compared to urea formaldehyde resin during pressing.

In the embodiment shown in FIGS. 2 and 3, a balancing layer 5 is provided on a lower surface 9 of the substrate 1. The balancing layer 5 may be a powder based balancing layer being applied as a powder. The powder based balancing layer may comprise wood particles, such as lignocellulosic and/or cellulosic particles, and a binder, preferably a thermosetting binder, such as an amino resin. The balancing layer 5 may be a resin impregnated paper, preferably impregnated with a thermosetting binder. The balancing layer 5 may comprise a veneer layer, such as a wood veneer or cork veneer. The balancing layer 5 may comprise a veneer layer, such as wood veneer or cork veneer arranged on a sub-layer comprising wood particles, such as lignocellulosic and/or cellulosic particles, and a binder, preferably a thermosetting binder, such as an amino resin.

In the embodiment shown in FIGS. 2 and 3, the substrate 1 is a board, such as a wood-based board, a particleboard, a thermoplastic board, a plywood, a lamella core, etc. In other embodiments, the substrate may be a sheet, such as paper sheet, a non-woven, or a veneer layer, such as a wood veneer layer or a cork veneer layer.

Furthermore, a protective layer (not shown) may be applied to the veneer layer 3. The protective layer may be a coating, such as one or several lacquer layers. The coating may be an acrylate or methacrylate coating, such as polyurethane coating. The coating may comprise wear and/or scratch resistant particles. The protective layer may be an overlay paper comprising wear resistant particles. The protective layer may be a powder overlay, as described in WO 2011/129755, comprising processed wood fibres, a binder and wear resistant particles applied as mix on the veneer surface. If the protective layer comprises or is an overlay paper or a powder overlay, the protective layer is preferably applied before the step of applying heat and pressure. Thereby, the protective layer is cured and attached to the veneer layer in the same step as attaching the veneer layer 3 to the first and second layers 2 a, 2 b and to the substrate 1.

The veneered element 10 may further be treated in different ways, for example brushed, oiled, lacquered, waxed, etc.

A protective coating (not shown) may also be applied to the veneer layer 3 prior to pressing. In one embodiment, a wax powder is applied, for example, scattered, on the upper surface of the veneer layer, facing away from the substrate 1, prior to pressing. During pressing, the wax powder forms a protective coating of the veneered element 10.

A protective foil (not shown) may also be applied on the veneer layer 3 prior or after pressing. The protective foil may be thermoplastic foil, such as PU or PVC foil.

In the figures, the first layer 2 a and the second layer 2 b are shown as two separate layers. However, after pressing, the first layer 2 a and the second layer 2 b may flow into each other such that no border between the layers exists.

It is contemplated that there are numerous modifications of the embodiments described herein, which are still within the scope of the invention as defined by the appended claims. When the word “about” is used in this specification in connection with a numerical value, it is intended that the associated numerical value include a tolerance of +/−10% around the stated numerical value.

EXAMPLE

500 g/m2 of a powder composition comprising a dry mixture of wood powder, melamine formaldehyde resin and brown pigments was scattered on a HDF board for forming a first layer. A 0.6 mm oak veneer comprising large holes and cracks was sprayed with 25 g/m2 of water. 100 g/m2 of a powder composition comprising a dry mixture of wood powder, melamine formaldehyde resin and black pigments were scattered on the wet veneer for forming a second layer.

The veneer was positioned on top of the HDF board, the first and the second powder layers facing each other.

The HDF board and the veneer was heat pressed at 160° C. for 30 seconds using a pressing force of 40 bars, resulting in a veneered element wherein the black powder composition forming the second layer was visible in the tiny cracks and pores of the veneer and wherein the brown powder composition forming the first layer was visible in the large holes and cracks of the veneer.

Embodiments

1. A method to produce a veneered element, the method comprising

applying a first layer on a substrate,

applying a second layer on a veneer layer,

applying the veneer layer with the second layer applied thereto on the first layer such that the second layer is facing the first layer,

pressing the first layer, the second layer and the veneer layer together to form a veneered element, thereby material originating from the second layer permeates into the veneer layer, and

wherein, after pressing, the first layer is visible through at least one defect such as defect of the veneer layer.

2. A method according to embodiment 1, wherein, during pressing, the defect of the veneer layer is at least partially filled with material originating from the first layer.

3. A method according to embodiment 1 or 2, wherein applying the second layer on the veneer layer comprises applying a liquid on the veneer layer, and subsequently applying a dry powder on the veneer layer for forming the second layer.

4. A method according to embodiment 1 or 2, wherein the second layer is applied as a slurry.

5. A method according to any one of the preceding embodiments, wherein no second layer is attached to a defect of the veneer layer, such as the defect of the veneer layer.

6. A method according to any one of the preceding embodiments, wherein, during pressing, the second layer prevents material originating from the first layer from permeating into the veneer layer.

7. A method according to any one of the preceding embodiments, wherein the first layer comprises pigments and/or dyes.

8. A method according to any one of the preceding embodiments, wherein the first layer has a substantially uniform colour.

9. A method according to any one of the preceding embodiments, wherein the second layer is free from pigments and dyes.

10. A method according to any one of embodiments 1-7, wherein, after pressing, the second layer has a different colour than the first layer.

11. A method according to any one of the preceding embodiments, wherein the second layer is transparent or translucent after pressing.

12. A method according to any one of the preceding embodiments, wherein the first layer comprises a thermosetting binder.

13. A method according to any one of the preceding embodiments, wherein the second layer comprises a thermosetting binder.

14. A method according to any one of the preceding embodiments, wherein the first layer is applied as a dry powder.

15. A method according to any one of the preceding embodiments, wherein the substrate comprises comprise a wood-based board, a particleboard, a thermoplastic board, a plywood, a lamella core, a veneer layer, a sheet, or a non-woven.

16. A veneered element, comprising

a substrate,

a first layer arranged on the substrate,

a second layer arranged on the first layer, and

a veneer layer arranged on the second layer, wherein the first layer is visible through a defect such as hole, cavity, crack and/or knot of the veneer layer, and wherein material originating from the second layer is present in the veneer layer.

17. A veneered element according to embodiment 16, wherein no material originating from the second layer is present in the defect such as a hole a cavity, crack or knot of the veneer layer.

18. A veneered element according to embodiment 16 or 17, wherein the defect such as cavity crack, hole and/or knot of the veneer layer is at least partially filled with material originating from at least the first layer.

19. A veneered element according to any one of embodiments 16-18, wherein the second layer is transparent or translucent.

20. A veneered element according to any one of embodiment 16-19, wherein the second layer is adapted to prevent material originating from the first layer from permeating into the veneer layer.

21. A veneered element according to any one of embodiment 16-20, wherein the first layer comprises pigments and/or dyes.

22. A veneered element according to any one of embodiments 16-21, wherein the first layer has a substantially uniform colour.

23. A veneered element according to any one of embodiment 16-22, wherein the second layer is free from pigments and dyes.

24. A veneered element according to any one of embodiments 16-22, wherein the second layer has a different colour than the first layer.

25. A veneered element according to any one of embodiments 16-24, wherein the substrate comprises a wood-based board, a particleboard, a thermoplastic board, a plywood, a lamella core, a veneer layer, a sheet, or a non-woven. 

The invention claimed is:
 1. A method to produce a veneered element, the method comprising applying a first layer on a substrate, applying a second layer on a veneer layer, applying the veneer layer with the second layer applied thereto on the first layer such that the second layer is facing the first layer, pressing the first layer, the second layer and the veneer layer together to form a veneered element, whereby material originating from the second layer permeates into the veneer layer, and wherein, after pressing, the first layer is visible through at least one defect.
 2. A method according to claim 1, wherein, during pressing, the at least one defect of the veneer layer is at least partially filled with material originating from the first layer.
 3. A method according to claim 1, wherein applying the second layer on the veneer layer comprises applying a liquid on the veneer layer, and subsequently applying a dry powder on the veneer layer for forming the second layer.
 4. A method according to claim 1, wherein the second layer is applied as a slurry.
 5. A method according to claim 1, wherein no second layer is attached to one of the at least one defect of the veneer layer.
 6. A method according to claim 1, wherein, during pressing, the second layer prevents material originating from the first layer from permeating into the veneer layer.
 7. A method according to claim 1, wherein the first layer comprises pigments and/or dyes.
 8. A method according to claim 1, wherein the first layer has a substantially uniform colour.
 9. A method according to claim 1, wherein the second layer is free from pigments and dyes.
 10. A method according to claim 1, wherein, after pressing, the second layer has a different colour than the first layer.
 11. A method according to claim 1, wherein the second layer is transparent or translucent after pressing.
 12. A method according to claim 1, wherein the first layer comprises a thermosetting binder.
 13. A method according to claim 1, wherein the second layer comprises a thermosetting binder.
 14. A method according to claim 1, wherein the first layer is applied as a dry powder.
 15. A method according to claim 1, wherein the substrate comprises a wood-based board, a particleboard, a thermoplastic board, a plywood, a lamella core, a veneer layer, a sheet, or a non-woven. 